Battery And Capacitor Assembly For A Vehicle And A Method For Heating And Cooling The Battery And Capacitor Assembly

ABSTRACT

A battery and capacitor assembly for a hybrid vehicle includes a plurality of battery cells, a plurality of capacitor cells, a cooling plate, a pair of end brackets, and a housing. The plurality of capacitor cells are arranged adjacent to the plurality of battery cells such that the plurality of battery cells and the plurality of capacitor cells form a cell stack. The pair of end brackets are disposed at opposite ends of the cell stack and are attached to the cooling plate. The pair of end brackets compress the plurality of battery cells and the plurality of capacitor cells. The housing is attached to the cooling plate and encloses the cell stack and the pair of end brackets.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present disclosure is a divisional of U.S. patent application Ser.No. 15/208,143 filed on Jul. 12, 2016, which claims the benefit of U.S.Provisional Application No. 62/302,386, filed on Mar. 2, 2016. Theentire disclosures of these applications are incorporated herein byreference.

This application is related to U.S. Provisional Application No.62/302,372, filed on Mar. 2, 2016, and U.S. application Ser. No.15/208,112, filed on Jul. 12, 2016, and U.S. application Ser. No.15/434,765, filed on Feb. 16, 2017. The entire disclosure of each of theabove applications is incorporated herein by reference.

FIELD

The present disclosure relates to vehicle battery systems, and moreparticularly to battery and capacitor assemblies for a vehicle andmethods for heating and cooling the battery and capacitor assemblies.

BACKGROUND

The background description provided here is for the purpose of generallypresenting the context of the disclosure. Work of the presently namedinventors, to the extent it is described in this background section, aswell as aspects of the description that may not otherwise qualify asprior art at the time of filing, are neither expressly nor impliedlyadmitted as prior art against the present disclosure.

Hybrid vehicles typically use a powertrain system including an engine, astop-start or mild hybrid system including a starter/generator and/orone or more electric motors for propelling the vehicle. Duringoperation, current needs to be supplied to start the engine, to supplyloads connected to a vehicle power bus, to restart the engine, to drivethe electric motors or starter/generator to move the vehicle and/or torecharge the batteries. For example in some mild hybrids, the electricmotors or starter/generator drives the vehicle for brief periods such as1-2 seconds during restarts to eliminate engine hesitation as the enginecranks, starts and reaches idle or other engine speed (hereinafterreferred to as e-boost). As a result, significant engineering effort hasbeen invested to improve the battery systems of hybrid vehicles to meetthe increasing current loads.

The automotive industry has also proposed using batteries operating athigher voltage levels such as 24V, 36V and 48V and/or systemsincorporating supercapacitors or ultracapacitors. However, these systemsare fairly complex since they still need to operate with legacy 12Vvehicle systems and components.

Some vehicle battery systems include a 12V battery (having a highcapacity such as 100 Ah) in addition to a higher voltage battery, asupercapacitor or an ultracapacitor.

SUMMARY

In one example, the present disclosure describes a battery and capacitorassembly for a hybrid vehicle that includes a plurality of batterycells, a plurality of capacitor cells, a cooling plate, a pair of endbrackets, and a housing. The plurality of capacitor cells are arrangedadjacent to the plurality of battery cells such that the plurality ofbattery cells and the plurality of capacitor cells form a cell stack.The pair of end brackets are disposed at opposite ends of the cell stackand are attached to the cooling plate. The pair of end brackets compressthe plurality of battery cells and the plurality of capacitor cells. Thehousing is attached to the cooling plate and encloses the cell stack andthe pair of end brackets.

In one aspect, each of the plurality of battery cells and each of theplurality of capacitor cells has a pouch cell configuration. In anotheraspect, each of the plurality of battery cells is a lithium ion cell,and each of the capacitor cells is a supercapacitor cell and/or anultracapacitor cell.

In other aspects, the battery and capacitor assembly further includes apair of side brackets disposed on opposite sides of the cell stack andextending between the opposite ends of the cell stack. The side bracketsare attached to the end brackets and cooperate with the end brackets tocompress the plurality of battery cells and the plurality of capacitorcells.

In other aspects, the battery and capacitor assembly has a lengthextending between exterior end surfaces of the housing adjacent to theopposite ends of the cell stack, a width that extends between exteriorside surfaces of the housing, and a height that extends between anexterior bottom surface of the housing and an exterior top surface ofthe cooling plate.

In one aspect, the width and/or length is less than or equal to 260millimeters. In another aspect, the width is less than or equal to 200millimeters and the height is less than or equal to 260 millimeters. Inanother aspect, the length is less than or equal to 400 millimeters.

In another aspect, the cooling plate defines a coolant channel forpassing coolant through the cooling plate that absorbs heat from thecooling plate.

In another aspect, the battery and capacitor assembly further includes aplurality of heatsink plates disposed between adjacent ones of theplurality of battery cells and the plurality of capacitor cells andarranged to transfer heat to and from the cooling plate throughconduction.

In another aspect, the battery and capacitor assembly further includes aplurality of thermoelectric devices disposed between the cooling plateand the cell stack and configured to adjust a temperature of theplurality of battery cells and adjust a temperature of the plurality ofbattery cells independent of adjusting the temperature of the pluralityof battery cells.

In another aspect, at least one of the plurality of thermoelectricdevices is disposed between the cooling plate and the plurality ofbattery cells, and at least one of the plurality of thermoelectricdevices is disposed between the cooling plate and the plurality ofcapacitor cells.

In another aspect, the battery and capacitor assembly further includes atemperature distribution plate disposed between the plurality ofthermoelectric devices and the cell stack and in contact with thecooling plate and/or the plurality of thermoelectric devices. Theplurality of thermoelectric devices are in contact with the coolingplate.

In another aspect, each of the plurality of heatsink plates includes aplate-like body and a flange. The plate-like body is disposed betweenadjacent ones of the plurality of battery cells and the plurality ofcapacitor cells. The flange transfers heat to and from the temperaturedistribution plate through conduction using direct contact with thetemperature distribution plate and/or a filler material disposed betweenthe flange and the temperature distribution plate.

In another example, the present disclosure describes a battery andcapacitor assembly for a hybrid vehicle that includes a plurality ofbattery cells, a plurality of capacitor cells, a cooling plate, and aplurality of thermoelectric devices. The plurality of capacitor cellsare arranged adjacent to the plurality of battery cells such that theplurality of battery cells and the plurality of capacitor cells form acell stack. The plurality of thermoelectric devices are disposed betweenthe cooling plate and the cell stack. In addition, the plurality ofthermoelectric devices are configured to heat and cool the plurality ofbattery cells and heat and cool the plurality of capacitor cellsindependent of heating and cooling the plurality of battery cells.

In one aspect, at least one of the plurality of thermoelectric devicesis arranged to heat and cool the plurality of capacitor cells, and atleast one of the plurality of thermoelectric devices is arranged to heatand cool the plurality of battery cells.

In another aspect, a single one of the plurality of thermoelectricdevices is arranged to heat and cool the plurality of capacitor cells,and at least two of the plurality of thermoelectric devices are arrangedto heat and cool the plurality of battery cells.

In another aspect, each of the plurality of thermoelectric devices isaligned with one of the plurality of battery cells and the plurality ofcapacitor cells which the thermoelectric device is configured to heatand cool.

In another aspect, the battery and capacitor assembly further includes atemperature distribution plate disposed between the plurality ofthermoelectric devices and the cell stack and in contact with thecooling plate and/or the plurality of thermoelectric devices. Theplurality of thermoelectric devices are in contact with the coolingplate.

In another aspect, the plurality of thermoelectric devices are disposedwithin pockets in the cooling plate, and the temperature distributionplate captures the plurality of thermoelectric devices within thepockets. In another aspect, the temperature distribution plate ispartially inset in the cooling plate.

In another aspect, the battery and capacitor assembly further includes aplurality of heatsink plates disposed between adjacent ones of theplurality of battery cells and the plurality of capacitor cells. Theplurality of heatsink plates are arranged to transfer heat to and fromthe temperature distribution plate through conduction.

In other aspects, each of the plurality of heatsink plates includes aplate-like body and a flange. The plate-like body is disposed betweenadjacent ones of the plurality of battery cells and the plurality ofcapacitor cells. The flange transfers heat to and from the temperaturedistribution plate through conduction using direct contact with thetemperature distribution plate and/or a filler material disposed betweenthe flange and the temperature distribution plate.

In another example, the present disclosure describes a system forcontrolling temperatures of a plurality of battery cells and a pluralityof capacitor cells disposed within a common enclosure. The systemincludes a battery temperature sensor, a capacitor temperature sensor,and a control module. The battery temperature sensor measures thetemperature of the plurality of battery cells. The capacitor temperaturesensor measures the temperature of the plurality of capacitor cells. Thecontrol module controls an amount of current, voltage, and/or powersupplied to a plurality of thermoelectric devices to heat and cool theplurality of battery cells based on the battery cell temperature. Inaddition, the control module controls the amount of current, voltage,and/or power supplied to the plurality of thermoelectric devices to heatand cool the plurality of capacitor cells based on the capacitor celltemperature and independent of heating and cooling the plurality ofcapacitor cells.

In one aspect, the control module controls the amount of current,voltage, and/or power supplied to a first one of the plurality ofthermoelectric devices to one of heat and cool the plurality of batterycells, and controls the amount of current, voltage, and/or powersupplied to a second one of the plurality of thermoelectric devices toone of heat and cool the plurality of battery cells.

In another aspect, the control module heats the plurality of batterycells when the battery cell temperature is less than a firsttemperature, cools the plurality of battery cells when the battery celltemperature is greater than a second temperature. In another aspect, thecontrol module heats the plurality of capacitor cells when the capacitorcell temperature is less than a third temperature, and cools theplurality of capacitor cells when the capacitor cell temperature isgreater than a fourth temperature.

In another aspect, the third temperature is different than the firsttemperature, and the fourth temperature is different than the secondtemperature. In another aspect, the third temperature is less than thefirst temperature, and the fourth temperature is less than the secondtemperature. In another aspect, each of the first, second, third, andfourth temperatures is predetermined.

In another aspect, the control module determines the first temperaturebased on a target resistance of the plurality of battery cells, a targetamount of power supplied by the plurality of battery cells, and/or atarget capacity of the plurality of battery cells. In another aspect,the control module determines the third temperature based on a targetresistance of the plurality of capacitor cells, a target amount of powersupplied by the plurality of capacitor cells, and/or a target capacityof the plurality of capacitor cells.

In another aspect, the control module heats the plurality of batterycells when the battery cell temperature is less than a first temperatureif the plurality of battery cells are charging, and the control moduledoes not heat the plurality of battery cells when the battery celltemperature is less than the first temperature if the plurality ofbattery cells are discharging.

In another example, the present disclosure describes a method forcontrolling temperatures of a plurality of battery cells and a pluralityof capacitor cells disposed within a common enclosure. The methodincludes measuring the temperature of the plurality of battery cells,measuring the temperature of the plurality of capacitor cells, andcontrolling an amount of current, voltage, and/or power supplied to aplurality of thermoelectric devices to heat and cool the plurality ofbattery cells based on the battery cell temperature. The method furtherincludes controlling the amount of current, voltage, and/or powersupplied to the plurality of thermoelectric devices to heat and cool theplurality of capacitor cells based on the capacitor cell temperature andindependent of heating and cooling the plurality of capacitor cells.

In another aspect, the method further includes controlling the amount ofcurrent, voltage, and/or power supplied to a first one of the pluralityof thermoelectric devices to one of heat and cool the plurality ofbattery cells, and controlling the amount of current, voltage, and powersupplied to a second one of the plurality of thermoelectric devices toone of heat and cool the plurality of battery cells.

In another aspect, the method further includes heating the plurality ofbattery cells when the battery cell temperature is less than a firsttemperature, and cooling the plurality of battery cells when the batterycell temperature is greater than a second temperature. In anotheraspect, the method further includes heating the plurality of capacitorcells when the capacitor cell temperature is less than a thirdtemperature, and cooling the plurality of capacitor cells when thecapacitor cell temperature is greater than a fourth temperature.

In another aspect, the third temperature is different than the firsttemperature, and the fourth temperature is different than the secondtemperature. In another aspect, the third temperature is less than thefirst temperature, and the fourth temperature is less than the secondtemperature. In another aspect, each of the first, second, third, andfourth temperatures is predetermined.

In another aspect, the method further includes determining the firsttemperature based on a target resistance of the plurality of batterycells, a target amount of power supplied by the plurality of batterycells, and/or a target capacity of the plurality of battery cells. Inanother aspect, the method further includes determining the thirdtemperature based on a target resistance of the plurality of capacitorcells, a target amount of power supplied by the plurality of capacitorcells, and/or a target capacity of the plurality of capacitor cells.

In another aspect, the method further includes heating the plurality ofbattery cells when the battery cell temperature is less than a firsttemperature if the plurality of battery cells are charging, and notheating the plurality of battery cells when the battery cell temperatureis less than the first temperature if the plurality of battery cells aredischarging.

Further areas of applicability of the present disclosure will becomeapparent from the detailed description, the claims and the drawings. Thedetailed description and specific examples are intended for purposes ofillustration only and are not intended to limit the scope of thedisclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure will become more fully understood from thedetailed description and the accompanying drawings, wherein:

FIG. 1A is a functional block diagram of an example of a powermanagement system for supplying power from and recharging of a batteryand a capacitor according to the present disclosure;

FIG. 1B is a more detailed functional block diagram of an example of apower management module in FIG. 1A;

FIG. 1C is a cross-sectional view of an integrated battery and capacitorassembly with heating and cooling capability according to the presentdisclosure;

FIG. 1D is a cross-sectional view of a portion of the integrated batteryand capacitor assembly of FIG. 1C within a circle 1D shown in FIG. 1C;

FIG. 1E is a partially exploded perspective view of the integratedbattery and capacitor assembly of FIG. 1C;

FIG. 1F is an exploded front view of an example of a battery cell or acapacitor cell according to the present disclosure;

FIG. 2 is a flowchart illustrating an example of a method forcontrolling temperatures of the battery and the capacitor according tothe present disclosure;

FIG. 3 is a graph illustrating DC equivalent series resistance (ESR) asa function of temperature for the capacitor; and

FIG. 4 is a graph illustrating cycle life as a function of celloperating temperature for the battery.

In the drawings, reference numbers may be reused to identify similarand/or identical elements.

DETAILED DESCRIPTION

In systems and methods for supplying power in a hybrid vehicle accordingto the present disclosure, higher current loads that occur duringstarting or e-boost events are predominantly supplied by a capacitorsuch as a supercapacitor or an ultracapacitor. Current is also suppliedby a battery at a limited and controlled rate during these events. As aresult, the capacity and physical size of the battery can besubstantially reduced while keeping the discharge rate (or C-rate) ofthe battery to a reasonable level.

In conventional battery systems, cranking after a “key-on” event issolely supported by the battery. As a result, the battery needs to havea sufficient capacity and discharge rate. The discharge rate or C-ratingis defined as a ratio of current/capacity. For example, a first batterycan supply 850A and has a capacity of 100 Ah (C-rate of 850A/100Ah=8.5). In contrast, a second battery can supply 850A and has acapacity of 17 Ah (C-rate of 850N17 Ah=50). While both batteries supplythe same amount of current, the second battery will have a significantlyshorter battery life than the first battery in similar applications. Inother words, the C-rate of the battery directly affects battery life andhigher C-rates correspond to shorter battery life.

Unlike other hybrid battery topologies, the battery used in the powermanagement system according to the present disclosure does notindependently support key-on engine starting. The main function of thebattery is to directly support vehicle loads such as boardnet loads. Thebattery also supplies controlled and limited current flow to indirectlysupport key-on engine starts and hybrid drive cycle events such asengine re-starting and/or electric boost. The battery is also used torecharge the capacitor after cranking.

Power supplied during regenerative/engine braking is used to rechargethe capacitor rather than the battery. Power from the capacitor is fedto the battery at a limited and controlled rate over time, which reducesbattery peak charge loads. In the systems and methods described herein,battery requirements are driven by energy rather than voltage drop atcranking amps, which allows a smaller capacity battery to be used.

The present disclosure can also be configured to support pulse-typevehicle loads, such as electric turbo systems or electric activesuspension systems, by selectively supplying current from the capacitorvia an AC/DC converter and/or a starter generator controller. Having thecapacitor supply the pulse-type vehicle loads improves battery life andminimizes the requirements, size and cost of the battery.

The specifications of the battery can be varied based on the severity ofthe hybrid drive cycle and pulse-type boardnet loads that are expectedfor a given application. In general, the battery requirements, size andcost will be lower than hybrid topologies where the battery directly orsubstantially contributes to the hybrid drive cycle.

The packaging cost of the battery and wiring are greatly reduced thoughintegration of the battery into an integrated battery and capacitorassembly. Additional packaging details of the integrated battery andcapacitor assembly can be found in U.S. Application No. 62/302,372,filed on Mar. 2, 2016, which is incorporated by reference in itsentirety.

Referring now to FIG. 1A, a power management system 100 for controllingthe supply of power from and recharging of a battery 108 and a capacitor110 is shown. In some examples, the battery includes a 12 V batteryincluding multiple battery cells connected in series and/or parallel topositive and negative battery terminals. In some examples, the batterycells are made using lithium iron phosphate (LiFePO₄) chemistry. Inother examples, the battery cells are made using lithium titanate(Li₄Ti₅O₁₂) (LTO) chemistry, other lithium ion chemistry, or otherbattery chemistry. In some examples, the battery 108 includes pouchcells arranged in a 4sNp configuration. In some examples, the battery108 provides 12.8 V nominal (8.0V to 14.4 V) and has a capacity of 20Ah/256 Wh. In other examples, the battery has a capacity less than orequal to 20 Ah and a C-rate less than or equal to 6.

In some examples, the capacitor 110 includes multiple capacitor cellsconnected in series and/or parallel to positive and negative capacitorterminals. In some examples, the capacitor 110 includes supercapacitorsor ultracapacitors. In some examples, the capacitor 110 provides 12V,24V, 36V, or 48V nominal (0-54 V). In some examples, a pouch cell formatis used for capacitor cells in the capacitor. In some examples, thecapacitors are connected in an 18sNp configuration and have a capacityof 0.6 Ah (30 Wh).

A power management module 112 controls the supply of power from andrecharging of the battery 108 and the capacitor 110. The powermanagement module 112 may communicate over a vehicle data bus 114 withother vehicle controllers and/or with components of the power managementsystem 100. The power management module 112 may transmit data such asstate of charge (SOC) and state of health (SOH) for the battery 108 andthe capacitor 110 to other vehicle controllers. In some examples, thevehicle data bus 114 includes a CAN bus, although other data bus typescan be used. In some examples, the power management module 112 receivesinformation such as key-on events, vehicle speed, drive mode events,engine oil temperature, regeneration events, e-boost events or othercontrol information from other vehicle controllers. Vehicle speed may beindicative of a future regeneration event. Engine oil temperature may beindicative of engine load during cranking. The power management module112 may adjust operation of the power management system 100 based onthese signals.

In some operating modes, the power management module also controls thesupply of current to a vehicle power bus 102 and vehicle loads 104 suchas boardnet loads. The power management module 112 receives batteryoperating parameters from one or more sensors such as temperaturesensors 130 and/or voltage sensors 132. In some examples, thetemperature sensors 130 and the voltage sensors 132 monitor temperaturesand voltages at the battery cell level. The power management module 112also receives capacitor operating parameters from one or more sensorssuch as temperature sensors 136 and/or voltage sensors 138. In someexamples, the temperature sensors 136 and the voltage sensors 138monitor temperatures and voltages at the capacitor cell level.

Temperature control of the battery 108 and/or the capacitor 110 may beprovided by thermoelectric devices (TEDs) 140 and 142, respectively. ATED driver circuit 146 controls the TEDs 140 and 142. The powermanagement module 112 selectively actuates the TED driver circuit 146 asneeded to adjust the amount of current, voltage, and/or power suppliedto the TEDs 140 and 142 and thereby control the temperature of thebattery 108 and the capacitor 110. In some examples, the TEDs 140 and/or142 include one or more heating/cooling zones that allow individual andindependent temperature control of one or more battery cells orcapacitor cells.

In some cases, when controlling the TEDs 140 and 142 to cool the battery108 and/or the capacitor 110, increasing the amount of current, voltage,and/or power supplied to the TEDs 140 and 142 may increase the amount ofcooling provided by the TEDs 140 and 142. However, increasing the amountof current, voltage, and/or power supplied to the TEDs 140 and 142 mayalso increase the amount of resistive heat provided by the TEDs 140 and142. Thus, in some cases, increasing the amount of current, voltage,and/or power supplied to the TEDs 140 and 142 may decrease the overallcooling effect of the TEDs 140 and 142. Therefore, the amount ofcurrent, voltage, and/or power supplied to the TEDs 140 and 142 may becontrolled based on a balance between the amount of cooling provided bythe TEDs 140 and 142 and the amount of resistive heat provided by theTEDs 140 and 142.

The power management module 112 may control the amount of current,voltage, and/or power supplied to the TEDs 140 and 142 based on theaforementioned balance to achieve a maximum temperature differenceacross the TEDs 140 and 142. The temperature difference across each ofthe TEDs 140 and 142 is an indicator of their respective overall coolingeffects. In some examples, the power management module 112 controls theTEDs 140 and 142 in an open-loop manner based on a predeterminedrelationship between (1) the amount of current, voltage, and/or powersupplied to the TEDs 140 and 142 and (2) the temperature differenceacross the TEDs 140 and 142. In some conditions, the power managementmodule 112 adjusts or selects the predetermined relationship based onthe age and/or temperature of the battery 108 and/or the capacitor 110.

In some examples, the power management module 112 controls the amount ofcurrent, voltage, and/or power supplied to the TEDs 140 and 142 in aclosed-loop manner based on a measured temperature difference across theTEDs 140 and 142. For example, the power management module 112 mayadjust the amount of current, voltage, and/or power supplied to the TEDs140 and 142 to maximize their measured temperature differences andthereby maximize their cooling effects.

In contrast, when controlling the TEDs 140 and 142 to heat the battery108 and/or the capacitor 110, resistive heating adds to, rather thandetracts from, the overall heating effect of the TEDs 140 and 142. Thus,in some examples, the power management module 112 always increases theamount of current, voltage, and/or power supplied to the TEDs 140 and142 to increase the amount of heat provided by the TEDs 140 and 142.

A current detector circuit 150 detects current supplied by the batteryor supplied to the battery during recharging. The current detectorcircuit 150 may be arranged between a negative terminal of the battery108 and chassis ground 152. A current detector circuit 156 detectscurrent supplied by the capacitor 110 or supplied to the capacitor 110during recharging. The current detector circuit 156 may be arrangedbetween a negative terminal of the capacitor 110 and the chassis ground152. The current detector circuits 150 and 156 provide sensed batterycurrent and capacitive current values, respectively, to the powermanagement module 112.

An overvoltage protection circuit 160 may be arranged between a positiveterminal of the battery 108 and loads such as the vehicle power bus 102.The overvoltage protection circuit 160 monitors a voltage output of thebattery and provides a voltage value to the power management module 112.The overvoltage circuit 160 protects the battery from overcharging whenone or more cells is at or above a voltage limit of the battery cell.Another function of the overvoltage circuit 160 is to protect thebattery from excessive current. If an over voltage condition isdetected, the battery 108 may be disconnected or other actions may betaken. For example, excessive voltage or current may occur duringcharging with an external charger.

In some examples, the power management module 112 performs batterymanagement including cell voltage measurement, cell balancing,temperature measurement, current limits calculations, state of charge(SOC) estimation and/or state of health (SOH) estimation based on themeasured battery parameters. In some examples, the power managementmodule 112 also performs capacitor management including cell voltagemeasurement, cell balancing, temperature measurement, current limitscalculations, SOC estimation and/or SOH estimation based on measuredcapacitor parameters.

A DC/DC converter 161 may be provided to control flow of the currentbetween the battery 108, the capacitor 110 and/or a starter/generator174. In some examples, the DC/DC converter 161 includes a DC/DC boostconverter 162 and a DC/DC buck converter 164 that are connected betweenthe battery 108, the capacitor 110 and the starter/generator 174. Insome examples, the DC/DC boost converter 162 has an input range of 8V to16V and a current input range of 0-100 Amps. In some examples, the DC/DCboost converter 162 has an output range of 24V to 54V and a currentoutput range of 0-67 Amps.

In some examples, the DC/DC buck converter 164 has an input range of 24Vto 54V and a current input range of 0-53 Amps. In some examples, theDC/DC buck converter 164 has an output range of 8V to 16V and a currentoutput range of 0-80 Amps. As can be appreciated, the ratings of theDC/DC boost converter 162 and the DC/DC buck converter 164 will vary fordifferent applications.

A starter/generator controller 170 is connected to the DC/DC boostconverter 162, the DC/DC buck converter 164, and the capacitor 110. Thestarter/generator controller 170 is also connected to a DC/AC converter172, which is connected to the starter/generator 174. Thestarter/generator 174 is connected to an engine (not shown). In someexamples, one or more electric motors 175 for driving the wheels may beprovided.

The vehicle power bus 102 may also be connected to an electric turbo 180and/or an active suspension system 182, which operate at the voltage ofthe battery 108. Alternately, an electric turbo 184 and/or an activesuspension system 186 may be connected to the starter/generatorcontroller 170 and/or the DC/AC converter 172 if they operate at highervoltages such as 24V, 36V, 48V, etc.

In some examples, a key-on starter 176 may be connected to thestarter/generator controller 170 and may be provided for starting largerdisplacement engines requiring higher starting current. The key-onstarter 176 may be supplied by current from the capacitor 110 andassisted in a limited and controlled manner by current supplied by thebattery 108 as described above.

Referring now to FIG. 1B, an example of the power management module 112is shown in further detail. The power management module 112 includes abattery monitoring module 192, a capacitor monitoring module 194 and acontrol module 196. The battery monitoring module 192 receives cellvoltages, battery current, cell temperatures and/or string voltage asdescribed above in FIG. 1A. The battery monitoring module 192 performscell balancing, calculates state of charge (SOC) and/or state of health(SOH) values for the battery 108. The capacitor monitoring module 194also receives cell voltages, capacitor current, cell temperatures and/orstring voltage as described above in FIG. 1A. The capacitor monitoringmodule performs cell balancing, calculates SOC and/or calculates SOH forthe capacitor 110.

The control module 196 communicates with the battery monitoring module192 and the capacitor monitoring module 194. The control module 196 mayalso receive information such as key-on events, vehicle speed, engineoil temperature, drive mode events, regeneration events, e-boost eventsor other control information from other vehicle controllers via thevehicle data bus 114. The control module 196 may also share SOC and SOHvalues for the battery 108 and the capacitor 110 with other vehiclecontrollers via the vehicle data bus 114.

The control module 196 enables and disables the DC/DC converter 161. Forexample, the control module enables and disables the DC/DC buckconverter 164 and the DC/DC boost converter 162 as needed during thevarious drive or operating modes. The control module 196 also monitorsoperation of the overvoltage protection circuit 160. The control module196 also communicates with the TED driver circuit 146 to controlheating/cooling of zones in the TEDs 140 and 142 associated with thebattery 108 and the capacitor 110.

Referring now to FIGS. 1C and 1E, an example of a battery and capacitorassembly 200 is shown. The battery and capacitor assembly 200 includesthe battery 108, the capacitor 110, and a cooling plate assembly 202.The battery 108 and the capacitor 110 include cells 204 and 206,respectively, that are arranged adjacent one another so as to form acell stack 208. Each of the cells 204 and/or 206 may be pouch-typecells.

The cells 204 and 206 have terminals or tabs 209 and 210, respectively,for conducting current to and from the cells 204 and 206. The tabs 209and 210 extend from top surfaces 212 and 214, respectively, of the cells204 and 206. In FIGS. 1C and 1E, the cells 204 and 206 are arranged withtheir side surfaces facing downward such that the tabs 209 and 210extend toward a side 216 of the battery and capacitor assembly 200 shownin FIG. 1E. Alternatively, the cells 204 and 206 may be arranged withtheir bottom surfaces facing upward such that the tabs 209 and 210extend toward a bottom end 218 of the battery and capacitor assembly 200shown in FIG. 1C.

End brackets 220 are positioned at opposite ends 222 and 224 of the cellstack 208, alongside outwardly-facing surfaces of outer ones of thecells 204 and 206, such that the cells 204 and 206 are arranged betweenthe end brackets 220. In some examples, the end brackets 220 have agenerally “L”-shaped cross section as shown in FIG. 1C. In someexamples, the end brackets 220 are made from metal (e.g., sheet metal).As shown in FIG. 1E, each of the end brackets 220 may include aplate-like body 226 and a flange 228 extending from an end of theplate-like body 226 at an angle (e.g., 90 degrees) relative to theplate-like body 226. The end brackets 220 are attached to the coolingplate assembly 202 by, for example, inserting a fastener through theflanges 228 of the end brackets 220 and into the cooling plate assembly202. The end brackets 220 provide a compressive force on the pouch-typecapacitive and battery cells located therebetween during operation. Inaddition, the end brackets 220 secure the cell stack 208 to the coolingplate assembly 202.

Side brackets 232 are positioned on opposite sides of the cell stack 208and extend between the ends 222 and 224 of the cell stack 208. In someexamples, two side brackets may be position on each side of the cellstack 208, yielding a total of four side brackets. In some examples, theside brackets 232 have a generally “C”-shaped cross section as shown inFIG. 1E. In some examples, each of the side brackets 232 has a width Wb(FIG. 1C) in a range from 0.25 inches to 0.75 inches (e.g., 0.5 inches).In some examples, the side brackets 232 are made from metal (e.g., sheetmetal). During assembly, the end brackets 220 may be positioned at theends 222 and 224 of the cell stack 208 and attached to the cooling plateassembly 202. The end brackets 220 may be held in a position to apply acompressive force to the cell stack 208 using a compression fixture. Theside brackets 232 may then be fit over and attached to the end brackets220, and the compression fixture may be removed. Thus, the side brackets232 may cooperate with the end brackets 220 to compress the cells 204and 206 in the cell stack 208.

Heatsink plates 234 are arranged between the cells 204 and 206 todissipate heat. In some examples, the heatsink plates 234 have agenerally “L”-shaped cross section as shown in FIG. 1C. In someexamples, the heatsink plates 234 are made from metal (e.g., aluminum).As shown in FIG. 1E, each of the heat sink plates 234 may include aplate-like body 236 and a flange 238 extending from the plate-like body236 at an angle (e.g., 90 degrees) relative to the plate-like body 236.

The flanges 238 of the heatsink plates 234 are in thermal contact withan outer bottom surface 230 of a temperature distribution plate 248 ofthe cooling plate assembly 202 so as to transfer heat to and from thetemperature distribution plate 248 through conduction. For example, theflanges 238 of the heatsink plates 234 may directly contact the bottomsurface 230. Alternatively, with brief reference to FIG. 1D, there maybe a gap 240 between the flanges 238 and the bottom surface 230 to allowvertical movement of the heatsink plates 234, and a filler material 242may be disposed in the gap 240. The filler material 242 may includegrease, epoxy, foam, and/or another suitable type of material fortransferring heat between the heat sink plates 234 and the cooling plateassembly 202 via conduction.

Referring again to FIGS. 1C and 1E, the cooling plate assembly 202includes a cooling plate 244, the TEDs 140 and 142, and the temperaturedistribution plate 248. In some examples, the cooling plate 244 isformed (e.g., cast or machined) from metal (e.g., aluminum). In someexamples, the TEDs 140 and 142 are embedded in the cooling plate 244,and the temperature distribution plate 248 captures the TEDs 140 and 142within the cooling plate 244. In some examples, the cooling plate 244defines pockets or raised mounting areas, the TEDs 140 and 142 arepositioned within the pockets or on the raised mounting areas, and thetemperature distribution plate 248 is attached to the cooling plate 244to capture the TEDs 140 and 142 within the pockets or raised mountingareas. In addition, the temperature distribution plate 248 may bepartially inset in the cooling plate 244 and project from a bottomsurface 252 thereof as shown in FIG. 1C. Alternatively, the temperaturedistribution plate 248 may be completely proud of the cooling plate 244on a raised mounting area on the cooling plate 244.

The temperature distribution plate 248 dissipates or spreads out hot orcold spots along surfaces thereof to equalize temperature variation. Insome examples, the temperature distribution plate 248 may also be splitinto zones with thermal separation therebetween so that the battery 108and the capacitor 110 may be maintained at different temperatures. Forexample, the temperature distribution plate 248 may include a firstplate positioned adjacent to the cells 204 of the battery 108, and asecond plate positioned adjacent to the cells 206 of the capacitor 110and thermally insulated from the first plate. In some examples, thetemperature distribution plate 248 is formed (e.g., stamped) from metal(e.g., aluminum).

The TEDs 140 and 142 are arranged in one or more heating/cooling zonesto independently control the temperatures of the zones and/or of cellsdisposed therein. The zones may be thermally insulated from one anotherusing, for example, an air gap disposed between the zones. In theexample shown, the TED(s) 140 consists of a single TED arranged in azone 108-1 of the battery 108, and the TED(s) 142 includes TEDs 142-1,142-2, 142-3, and 142-4 arranged in zones 110-1, 110-2, 110-3, and110-4, respectively, of the capacitor 110. The TED(s) 140 is arranged tocontrol the temperature(s) of the cells 204 of the battery 108 and/orthe zone(s) in which the cells 204 are disposed. For example, the TED(s)140 may be disposed above the cells 204, adjacent to the cells 204,and/or aligned with the cells 204 along a longitudinal axis 254 of thebattery and capacitor assembly 200 shown in FIG. 1C.

The TEDs 142-1 through 142-4 are arranged to control the temperature(s)of cells 206 of the capacitor 110 and/or the zone(s) in which the cells204 are disposed. For example, the TEDs 142-1 through 142-4 may bedisposed above the cells 206, adjacent to the cells 206, and/or alignedwith the cells 206 along the longitudinal axis 254. Thus, the TEDs 140and 142 may be used to independently control the temperatures of thecells 204 and 206, respectively. In some examples, multiple TEDs may beused in place of the TED(s) 140 to control the temperature(s) of thecells 204 of the battery 108. In some examples, a single TED may be usedin place of the TEDs 142-1 through 142-4 to control the temperature(s)of the cells 206 of the capacitor 110.

The temperatures sensors 130 are arranged adjacent to the battery cells204 to measure the temperature thereof. For example, the temperaturesensors 130 may be positioned between the top surfaces 212 of thebattery cells 204 and an interior surface of the side 216 of the batteryand capacitor assembly 200 as shown in FIG. 1E. In other examples, thetemperature sensors 130 may be positioned in or on the TED(s) 140, or ona busbar (not shown) that connects the tabs 209 of the battery cells 204to each other. In some examples, the temperature sensors 130 may includea temperature sensor for each of the battery cells 204. In someexamples, a single temperature sensor may be used to measure thetemperature of all of the battery cells 204.

The temperatures sensors 136 are arranged adjacent to the capacitorcells 206 to measure the temperature thereof. For example, thetemperature sensors 136 may be positioned between the top surfaces 214of the capacitor cells 206 and the interior surface of the side 216 ofthe battery and capacitor assembly 200 as shown in FIG. 1E. In otherexamples, the temperature sensors 130 may be positioned in or on one ormore (e.g., all) of the TEDs 142-1 through 142-4, or on a busbar (notshown) that connects the tabs 210 of the capacitor cells 206 to eachother. In some examples, the temperature sensors 136 may include atemperature sensor for each of the capacitor cells 206. In someexamples, a single temperature sensor may be used to measure thetemperature of all of the capacitor cells 206.

In some examples, the temperature sensors 130 are arranged within one ormore zones in which the battery cells 204 are disposed in order tomeasure the temperature(s) of the zones. In the example shown, thetemperature sensors 130 are positioned within the zone 108-1 of thebattery 108. In some examples, the temperature sensors 136 are arrangedwithin one or more zones in which the capacitor cells 206 are disposedin order to measure the temperature(s) of the zones. In the exampleshown, the temperature sensors 136 include temperature sensors 136-1,136-2, 136-3, and 136-4 that are arranged in the zones 110-1, 110-2,110-3, and 110-4, respectively, of the capacitor 110. In addition, aplurality (e.g., five) of the capacitor cells 206 are disposed in eachof the zones 110-1 through 110-4.

In some examples, the cooling plate 244 defines one or more coolantchannels 256 through which coolant flows. Coolant flowing through thecoolant channels 256 absorbs heat from the cooling plate 244. As shownin FIG. 1C, the coolant channels 256 have an inlet 256-1 and an outlet256-2. Coolant enters the coolant channels 256 through the inlet 256-1and exits the coolant channels 256 through the outlet 256-2.

In the example shown, the inlet 256-1 and the outlet 256-2 are disposedat opposite ends of the cooling plate 244. Alternatively, the inlet256-1 and the outlet 256-2 may be disposed on the same side of thecooling plate 244. In addition, the coolant channels 256 maycollectively form a generally “U”-shaped channel that extends from theinlet 256-1 to the outlet 256-2, and cooling fins (not shown) may bedisposed in the “U”-shaped channel. The cooling fins increase the amountof heat transfer between the cooling plate 244 and the coolant flowingthrough the coolant channels 256, and may separate the coolant channels256 while allowing coolant to flow therebetween.

In some examples, the DC/DC boost converter 162 and the DC/DC buckconverter 164 are in thermal contact (or a heat exchange relationship)with an outer top surface 258 of the cooling plate assembly 202.Likewise, the DC/AC converter 172 is also in thermal contact (or a heatexchange relationship) with the outer surface 258 of the cooling plateassembly 202.

A housing 260 cooperates with the cooling plate 244 to completelyenclose the cell stack 208. As shown in FIG. 1E, the housing 260 has abox shape with a closed bottom 262, an open top 264, and sides 266, 268,270, and 272. The housing 260 may be attached to the cooling plateassembly 202 by, for example, inserting fasteners through the sides 266and 270 of the housing 260 and into the cooling plate 244, or insertingfasteners from a flange (not shown) located at the top of the sides 266,268, 270, and 272 into the cooling plate 244. In some examples, thehousing 260 is made from metal and/or plastic. In some examples, thepower management module 112 is also disposed within the housing 260.

The integration of the battery 108 and the capacitor 110 within a singlehousing is enabled by the smaller physical size of the battery 108relative the physical size of a conventional hybrid battery. Forexample, whereas a conventional hybrid battery may have a physical sizeassociated with a capacity of 100 Ah, the battery 108 may have aphysical size associated with a capacity of 17 Ah. The smaller physicalsize of the battery 108 is enabled by primarily using the capacitor 110and only indirectly using the battery 108 to support higher currentloads that occur during starting or e-boost events, and by limiting thedischarge rate (or C-rate) of the battery 108. Additional powermanagement details can be found in U.S. Application No. 62/302,372,filed on Mar. 2, 2016.

With continued reference to FIG. 1E, the battery and capacitor assembly200 has a length L, a width W, and a height H. The length L extends froman exterior surface of the side 266 of the housing 260 to an exteriorsurface of the side 270 of the housing 260. The width W extends from anexterior surface of the side 268 of the housing 260 to an exteriorsurface of the side 272 of the housing 260. The height H extends from anexterior surface of the bottom 262 of the housing 260 to a top surface274 of the housing 260 and extends around the open top 264 of thehousing 260.

The dimensions of the battery and capacitor assembly 200 may becomparable to the dimensions of a conventional lead acid battery. Forexample, the width W may be less than or equal to 200 millimeters (mm),the height H may be less than or equal to 260 mm, and the length L maybe less than or equal to 400 mm. In some examples, the width W may be ina range from 170 mm to 200 mm, the height H may be in a range from 200mm to 260 mm, and the length L may be in a range from 300 mm to 400 mm.

The aforementioned dimensions may apply when the cells 204 and 206 arearranged with their side surfaces facing downward as shown in FIGS. 1Cand 1E. Thus, if the cells 204 and 206 are arranged with their bottomsurfaces facing downward, the numerical ranges for the width W and theheight H may be reversed. For example, the width W may be in a rangefrom 200 mm to 260 mm, the height H may be in a range from 170 mm to 200mm.

The dimensions of the battery and capacitor assembly 200 may bequantified relative to the dimensions of the cells 204 and 206 of thebattery 108 and the capacitor 110, respectively. For example, each ofthe cells 204 and 206 may have dimensions D1, D2, and D3 aligned withthe width W, the height H, and the length L, respectively, of thebattery and capacitor assembly 200. The dimension D1 may be in a rangefrom 120 mm to 140 mm (e.g., 130 mm), the dimension D2 may be in a rangefrom 145 mm to 165 mm (e.g., 140 mm), and a sum of the dimension D3 forall of the cells 204 and 206 may be in a range from 240 mm to 260 mm(e.g., 250 mm).

The width W of the battery and capacitor assembly 200 may be greaterthan the dimension D1 of each of the cells 204 and 206 by an amount in arange from 50 percent to 60 percent (e.g., 54 percent). The amount bywhich the width W is greater than the dimension D1 may provide clearancefor a thickness T of the housing 260 and for the tabs 209 and 210 of thecells 204 and 206, respectively. In addition, the power managementmodule 112 may be positioned between (1) the tabs 209 and 210 and (2)the housing 260, and the amount by which the width W is greater than thedimension D1 may provide clearance for the power management module 112.

The height H of the battery and capacitor assembly 200 may be greaterthan the dimension D2 of each of the cells 204 and 206 by an amount in arange from 10 percent to 20 percent (e.g., 12 percent). The amount bywhich the height H is greater than the dimension D2 may provideclearance for the thickness T of the housing 260. The length L of thebattery and capacitor assembly 200 may be greater than a sum of thedimension D3 for all of the cells 204 and 206 by an amount in a rangefrom 15 percent to 25 percent (e.g., 20 percent). The amount by whichthe length L is greater than the dimension D3 may provide clearance forthe thickness T of the housing 260, for the end brackets 220, and forthe tolerance stack-up of the cells 204 and 206.

The dimension D1 of the cells 204 and 206 may be aligned with the widthW and the dimension D2 may be aligned with the height H when the cells204 and 206 are arranged with their side surfaces facing downward asshown in FIGS. 1C and 1E. In contrast, if the cells 204 and 206 arearranged with their bottom surfaces facing downward, the dimension D1 ofthe cells 204 and 206 may be aligned with the height H and the dimensionD2 may be aligned with the width W. In this case, dimension D1 may be ina range from 145 mm to 165 mm (e.g., 140 mm), and the dimension D2 maybe in a range from 120 mm to 140 mm (e.g., 130 mm). In addition, thewidth W may be greater than the dimension D2 of each of the cells 204and 206 by an amount in a range from 10 percent to 20 percent (e.g., 12percent). In addition, the height H may be greater than the dimension D1of each of the cells 204 and 206 by an amount in a range from 50 percentto 60 percent (e.g., 54 percent).

Referring now to FIG. 1F, an example of a cell 300 having a pouchconfiguration is shown. The cell 300 may be representative of one of thecells 204 of the battery 108 and/or one of the cells 206 of thecapacitor 110. The cell 300 includes a housing 302, first electrodes(e.g., cathodes) 304, second electrodes (e.g., anodes) 306 andseparators 308 disposed adjacent ones of the first and second electrodes304 and 306.

The housing 302 includes a first side 310 and a second side 312. Duringassembly, the electrodes 304 and 306 and the separators 308 may bepositioned between the first and second sides 310 and 312, and the firstand second sides 310 and 312 may be joined together along seams 314. Inturn, the electrodes 304 and 306 and the separators 308 may be sealedwithin the housing 302. In some examples, the housing 302 is made fromplastic, and the first and second sides 310 and 312 are jointed togetheralong the seams 314 using adhesive and/or heat sealing.

Each of the electrodes 304 includes plate-like body 316 and a tab 318extending from one end of the plate-like body 316. Similarly, each ofthe electrodes 306 includes plate-like body 320 and a tab 322 extendingfrom one end of the plate-like body 320. The tabs 318 of the electrodes304 may cooperate to form one of the tabs 209 or 210 of the cells 204 or206, and the tabs 322 of the electrodes 306 may cooperate to form theother one of the tabs 209 or 210 on the same one of the cells 204 or206.

If the cell 300 is a lithium ion battery cell, the electrodes 304 and306 may be coated with lithium iron phosphate (LiFePO₄), lithiumtitanate (Li₄Ti₅O₁₂) (LTO), and/or other lithium ion chemistry orbattery chemistry. In addition, the cell 300 may store energyelectrochemically. If the cell 300 is a supercapacitor (orultracapacitor) cell, the electrodes 304 and 306 may be made from orcoated with activated carbon (AC), carbon fiber-cloth (AFC),carbide-derived carbon (CDC), carbon aerogel, graphite, graphene,graphane, carbon nanotubes (CNTs) and/or other supercapacitor chemistry.In addition, the cell 300 may store energy electrostatically on thesurfaces of the electrodes 304 and 306, and the energy storage of thecell 300 may not involve chemical reactions.

When the cell 300 discharges, energy-containing ions travel from one ofthe electrodes 304 or 306, through the one of separators 308, and to theother one of the electrodes 304 or 306. The movement of the ionsreleases energy, which may be extracted into an external circuit. Whenthe cell 300 charges, energy is used to move the ions back to the one ofthe electrodes 304 or 306 from which the lithium ions travelled. Theseparators 308 are formed from an electrically insulating material sothat the separators 308 electrically insulate the electrodes 304 and 306from one another.

Referring now to FIG. 2, a method 350 for controlling the temperature ofthe battery 108 and the capacitor 110 during operation is shown. Themethod 350 is described in the context of the modules included in theexample implementation of the power management module 112 shown in FIG.1B. However, the particular modules that perform the steps of the methodmay be different than the modules mentioned below and/or the method maybe implemented apart from the modules of FIG. 1B.

At 360, the control module 196 determines whether the key is on. When360 is true, the control module 196 monitors the temperature of thebattery cells 204 individually or monitors the temperature of one ormore zones in which the battery cells 204 are disposed. In someexamples, the control module 196 monitors the battery cell or zonetemperature using the temperature sensors 130. At 368, the controlmodule 196 determines whether the battery cell or zone temperature isless than a first temperature T1. If 368 is true, the control module 196heats the corresponding battery cell or zone using the TED(s) 140. Forexample, the control module 196 may heat the battery cells 204 disposedin the zone 108-1 when the temperature(s) measured by the temperaturesensors 130 is less than the first temperature T1.

If 368 is false, the control module 196 continues at 376 and determineswhether the battery cell or zone temperature is greater than a secondtemperature T2. If 376 is true, the control module 196 cools thecorresponding battery cell or zone using the TED(s) 140. For example,the control module 196 may cool the battery cells 204 disposed in thezone 108-1 when the temperature(s) measured by the temperature sensors130 is greater than the second temperature T2.

The control module 196 continues from 372, 376 or 378 and monitors atemperature of capacitor cells 206 individually or monitors thetemperature of one or more zones in which the capacitor cells 206 aredisposed. In some examples, the control module 196 monitors thecapacitor cell or zone temperature using the temperature sensors 136. At384, the control module 196 determines whether the capacitor cell orzone temperature is less than a third temperature T3. If 384 is true,the control module 196 continues at 338 and heats the correspondingcapacitor cell or zone using the TED(s) 142. For example, the controlmodule 196 may heat the capacitor cells 206 disposed in the zone 110-1when the temperature measured by the temperature sensor 136-1 is lessthe third temperature T3. Similarly, the control module 196 may heat thecapacitor cells 206 disposed in the zones 110-2, 110-3, or 110-4 whenthe temperature measured by the temperature sensors 136-2, 136-3, or136-4, respectively, is less the third temperature T3.

If 384 is false, the control module 196 continues at 390 and determineswhether the capacitor cell or zone temperature is greater than a fourthtemperature T4. If 390 is true, the control module 196 continues at 396and cools the corresponding battery cell or zone using the TED(s) 142.For example, the control module 196 may cool the capacitor cells 206disposed in the zone 110-1 when the temperature measured by thetemperature sensor 136-1 is greater than the fourth temperature T4.Similarly, the control module 196 may heat the capacitor cells 206disposed in the zones 110-2, 110-3, or 110-4 when the temperaturemeasured by the temperature sensors 136-2, 136-3, or 136-4,respectively, is greater than the fourth temperature T4.

In some examples, if the battery cell temperature is less than the firsttemperature, the control module 196 determines whether to heat thecorresponding battery cell or zone based on whether the battery 108 ischarging or discharging. If the battery cell temperature is less thanthe first temperature when the battery 108 is charging, the controlmodule 196 heats the corresponding battery cell or zone. If the batterycell temperature is less than the first temperature when the battery 108is discharging, the control module 196 does not heat the correspondingbattery cell or zone.

Referring now to FIG. 3, DC equivalent series resistance (ESR) is shownat 450 and capacitance is shown at 454 as a function of temperature forthe capacitor 110. Heating of the capacitor 110 above the thirdtemperature T3 (at 456) is performed to reduce ESR at low temperaturesto ensure high power and high capacity. This may be important for highpower loads such as cold starting and e-boost. Cooling of the capacitor110 below the fourth temperature T4 (at 458) is performed to improvecapacitor cell life.

Referring now to FIG. 4, cycle life is shown at 460 as a function ofcell operating temperature for the battery 108. Heating of the cells inthe battery above the first temperature T1 (at 466) is performed toensure low resistance, high power, full capacity, and long life. Thismay be important for high power loads such as cold starting. Cooling ofthe battery cells below the second temperature T2 (at 468) is performedto improve battery cell life.

In some examples, the first temperature T1 for the battery cells isdifferent than the third temperature T3 for the capacitor cells and/orthe second temperature T2 for the battery cells is different than thefourth temperature T4 for the capacitor cells. Since the TEDs arearranged in zones, different temperature ranges may be used to heat andcool the battery cells relative to the capacitor cells even though thebattery cells and capacitor cells are arranged in the common assemblydescribed above. In other examples, the first temperature T1 for thebattery cells is the same as the third temperature T3 for the capacitorcells and/or the second temperature T2 for the battery cells is the sameas the fourth temperature T4 for the capacitor cells.

For example, the first temperature T1 may be in a range from 5° C. to15° C., the second temperature may be in a range from 45° C. to 55° C.,the third temperature T3 may be in a range from −5° C. to 5° C., and thefourth temperature T4 may be in a range from 35° C. to 45° C., althoughother temperatures may be used. In another example, the firsttemperature T1 may be 10° C., the second temperature T2 may be 50° C.,the third temperature T3 may be 0° C., and the fourth temperature may be40° C.

In some examples, the first, second, third, and/or fourth temperaturesT1, T2, T3, and/or T4 are predetermined. In some examples, the controlmodule 196 determines the first temperature T1 and/or the secondtemperature T2 based on a target resistance of the battery cells 204, atarget amount of power supplied by the battery cells 204, a targetcapacity of the battery cells 204, and/or a target life of the batterycells 204. In some examples, the control module 196 determines the thirdtemperature T1 and/or the fourth temperature T4 based on a targetresistance of the capacitor cells 206, a target amount of power suppliedby the capacitor cells 206, a target capacity of the capacitor cells206, and/or a target life of the capacitor cells 206.

In one example, the capacity of the battery cells 204 may decrease attemperatures below 20° C., and the battery cells 204 may incurirreversible damage when the battery cells 204 are charged attemperatures below −20° C. Thus, the control module 196 may set thetemperature T1 to 20° C. when full battery capacity is desired.Otherwise, the control module 196 may set the temperature T1 to −20° C.

In one example, the control module 196 may determine the secondtemperature T2 based on a balance between the target amount of powersupplied by the battery cells 204 and the target life of the batterycells 204. For example, the second temperature T2 may normally be atemperature (e.g., 50° C.) above which the life of the battery cells 204decreases rapidly. However, if maximum battery power is desired, thecontrol module 196 may temporarily adjust the second temperature T2 to ahigher temperature (e.g., 60° C.).

The foregoing description is merely illustrative in nature and is in noway intended to limit the disclosure, its application, or uses. Thebroad teachings of the disclosure can be implemented in a variety offorms. Therefore, while this disclosure includes particular examples,the true scope of the disclosure should not be so limited since othermodifications will become apparent upon a study of the drawings, thespecification, and the following claims. It should be understood thatone or more steps within a method may be executed in different order (orconcurrently) without altering the principles of the present disclosure.Further, although each of the embodiments is described above as havingcertain features, any one or more of those features described withrespect to any embodiment of the disclosure can be implemented in and/orcombined with features of any of the other embodiments, even if thatcombination is not explicitly described. In other words, the describedembodiments are not mutually exclusive, and permutations of one or moreembodiments with one another remain within the scope of this disclosure.

As used herein, the phrase at least one of A, B, and C should beconstrued to mean a logical (A OR B OR C), using a non-exclusive logicalOR, and should not be construed to mean “at least one of A, at least oneof B, and at least one of C.” Spatial and functional relationshipsbetween elements (for example, between modules, circuit elements,semiconductor layers, etc.) are described using various terms such as“connected,” “adjacent,” “next to,” “on top of,” “inner,” “outer,”“beneath,” “below,” “lower,” “above,” “upper,” “bottom,” “top,” “side,”and “disposed.” Unless explicitly described as being “direct,” when arelationship between first and second elements is described in the abovedisclosure, that relationship can be a direct relationship where noother intervening elements are present between the first and secondelements, but can also be an indirect relationship where one or moreintervening elements are present (either spatially or functionally)between the first and second elements.

In addition, spatially relative terms may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. Spatiallyrelative terms may be intended to encompass different orientations ofthe device in use or operation in addition to the orientation depictedin the figures. For example, if the device in the figures is turnedover, elements described as “below” or “beneath” other elements orfeatures would then be oriented “above” the other elements or features.Thus, the example term “below” can encompass both an orientation ofabove and below. The device may be otherwise oriented (rotated 90degrees or at other orientations) and the spatially relative descriptorsused herein interpreted accordingly.

In this application, including the definitions below, the term “module”or the term “controller” may be replaced with the term “circuit.” Theterm “module” may refer to, be part of, or include: an ApplicationSpecific Integrated Circuit (ASIC); a digital, analog, or mixedanalog/digital discrete circuit; a digital, analog, or mixedanalog/digital integrated circuit; a combinational logic circuit; afield programmable gate array (FPGA); a processor circuit (shared,dedicated, or group) that executes code; a memory circuit (shared,dedicated, or group) that stores code executed by the processor circuit;other suitable hardware components that provide the describedfunctionality; or a combination of some or all of the above, such as ina system-on-chip.

The module may include one or more interface circuits. In some examples,the interface circuits may include wired or wireless interfaces that areconnected to a local area network (LAN), the Internet, a wide areanetwork (WAN), or combinations thereof. The functionality of any givenmodule of the present disclosure may be distributed among multiplemodules that are connected via interface circuits. For example, multiplemodules may allow load balancing. In a further example, a server (alsoknown as remote, or cloud) module may accomplish some functionality onbehalf of a client module.

The term code, as used above, may include software, firmware, and/ormicrocode, and may refer to programs, routines, functions, classes, datastructures, and/or objects. The term shared processor circuitencompasses a single processor circuit that executes some or all codefrom multiple modules. The term group processor circuit encompasses aprocessor circuit that, in combination with additional processorcircuits, executes some or all code from one or more modules. Referencesto multiple processor circuits encompass multiple processor circuits ondiscrete dies, multiple processor circuits on a single die, multiplecores of a single processor circuit, multiple threads of a singleprocessor circuit, or a combination of the above. The term shared memorycircuit encompasses a single memory circuit that stores some or all codefrom multiple modules. The term group memory circuit encompasses amemory circuit that, in combination with additional memories, storessome or all code from one or more modules.

The term memory circuit is a subset of the term computer-readablemedium. The term computer-readable medium, as used herein, does notencompass transitory electrical or electromagnetic signals propagatingthrough a medium (such as on a carrier wave); the term computer-readablemedium may therefore be considered tangible and non-transitory.Non-limiting examples of a non-transitory, tangible computer-readablemedium are nonvolatile memory circuits (such as a flash memory circuit,an erasable programmable read-only memory circuit, or a mask read-onlymemory circuit), volatile memory circuits (such as a static randomaccess memory circuit or a dynamic random access memory circuit),magnetic storage media (such as an analog or digital magnetic tape or ahard disk drive), and optical storage media (such as a CD, a DVD, or aBlu-ray Disc).

The apparatuses and methods described in this application may bepartially or fully implemented by a special purpose computer created byconfiguring a general purpose computer to execute one or more particularfunctions embodied in computer programs. The functional blocks,flowchart components, and other elements described above serve assoftware specifications, which can be translated into the computerprograms by the routine work of a skilled technician or programmer.

The computer programs include processor-executable instructions that arestored on at least one non-transitory, tangible computer-readablemedium. The computer programs may also include or rely on stored data.The computer programs may encompass a basic input/output system (BIOS)that interacts with hardware of the special purpose computer, devicedrivers that interact with particular devices of the special purposecomputer, one or more operating systems, user applications, backgroundservices, background applications, etc.

The computer programs may include: (i) descriptive text to be parsed,such as HTML (hypertext markup language) or XML (extensible markuplanguage), (ii) assembly code, (iii) object code generated from sourcecode by a compiler, (iv) source code for execution by an interpreter,(v) source code for compilation and execution by a just-in-timecompiler, etc. As examples only, source code may be written using syntaxfrom languages including C, C++, C#, Objective C, Haskell, Go, SQL, R,Lisp, Java®, Fortran, Perl, Pascal, Curl, OCaml, Javascript®, HTML5,Ada, ASP (active server pages), PHP, Scala, Eiffel, Smalltalk, Erlang,Ruby, Flash®, Visual Basic®, Lua, and Python®.

None of the elements recited in the claims are intended to be ameans-plus-function element within the meaning of 35 U.S.C. § 112(f)unless an element is expressly recited using the phrase “means for,” orin the case of a method claim using the phrases “operation for” or “stepfor.”

What is claimed is:
 1. A battery and capacitor assembly for a hybridvehicle, comprising: a plurality of battery cells; a plurality ofcapacitor cells arranged adjacent to the plurality of battery cells suchthat the plurality of battery cells and the plurality of capacitor cellsform a cell stack; a cooling plate; a pair of end brackets disposed atopposite ends of the cell stack and attached to the cooling plate, thepair of end brackets compressing the plurality of battery cells and theplurality of capacitor cells; and a housing attached to the coolingplate and enclosing the cell stack and the pair of end brackets.
 2. Thebattery and capacitor assembly of claim 1, wherein each of the pluralityof battery cells and each of the plurality of capacitor cells has apouch cell configuration.
 3. The battery and capacitor assembly of claim2, wherein each of the plurality of battery cells is a lithium ion cell,and each of the capacitor cells is at least one of a supercapacitor celland an ultracapacitor cell.
 4. The battery and capacitor assembly ofclaim 1, further comprising a pair of side brackets disposed on oppositesides of the cell stack and extending between the opposite ends of thecell stack, wherein the pair of side brackets is attached to the pair ofend brackets and cooperate with the pair of end brackets to compress theplurality of battery cells and the plurality of capacitor cells.
 5. Thebattery and capacitor assembly of claim 1, wherein: the battery andcapacitor assembly has a length extending between exterior end surfacesof the housing adjacent to the opposite ends of the cell stack, a widththat extends between exterior side surfaces of the housing, and a heightthat extends between an exterior bottom surface of the housing and anexterior top surface of the cooling plate; and at least one of the widthand length is less than or equal to 260 millimeters.
 6. The battery andcapacitor assembly of claim 5, wherein the width is less than or equalto 200 millimeters and the height is less than or equal to 260millimeters.
 7. The battery and capacitor assembly of claim 6, whereinthe length is less than or equal to 400 millimeters.
 8. The battery andcapacitor assembly of claim 1, wherein the cooling plate defines acoolant channel for passing coolant through the cooling plate thatabsorbs heat from the cooling plate.
 9. The battery and capacitorassembly of claim 1, further comprising a plurality of heatsink platesdisposed between adjacent ones of the plurality of battery cells and theplurality of capacitor cells and arranged to transfer heat to and fromthe cooling plate through conduction.
 10. The battery and capacitorassembly of claim 9, further comprising a plurality of thermoelectricdevices disposed between the cooling plate and the cell stack andconfigured to adjust a temperature of the plurality of battery cells andadjust a temperature of the plurality of capacitor cells independent ofadjusting the temperature of the plurality of battery cells.
 11. Thebattery and capacitor assembly of claim 10, wherein: at least one of theplurality of thermoelectric devices is disposed between the coolingplate and the plurality of battery cells; and at least one of theplurality of thermoelectric devices is disposed between the coolingplate and the plurality of capacitor cells.
 12. The battery andcapacitor assembly of claim 10, further comprising a temperaturedistribution plate disposed between the plurality of thermoelectricdevices and the cell stack and in contact with at least one of thecooling plate and the plurality of thermoelectric devices, wherein theplurality of thermoelectric devices are in contact with the coolingplate.
 13. The battery and capacitor assembly of claim 12, wherein eachof the plurality of heatsink plates includes a plate-like body disposedbetween adjacent ones of the plurality of battery cells and theplurality of capacitor cells, and a flange that transfers heat to andfrom the temperature distribution plate through conduction using atleast one of: direct contact with the temperature distribution plate;and a filler material disposed between the flange and the temperaturedistribution plate.
 14. A battery and capacitor assembly for a hybridvehicle, comprising: a plurality of battery cells; a plurality ofcapacitor cells arranged adjacent to the plurality of battery cells suchthat the plurality of battery cells and the plurality of capacitor cellsform a cell stack; a cooling plate; and a plurality of thermoelectricdevices disposed between the cooling plate and the cell stack andconfigured to heat and cool the plurality of battery cells and heat andcool the plurality of capacitor cells independent of heating and coolingthe plurality of battery cells.
 15. The battery and capacitor assemblyof claim 14, wherein: at least one of the plurality of thermoelectricdevices is arranged to heat and cool the plurality of capacitor cells;and at least one of the plurality of thermoelectric devices is arrangedto heat and cool the plurality of battery cells.
 16. The battery andcapacitor assembly of claim 15, wherein: a single one of the pluralityof thermoelectric devices is arranged to heat and cool the plurality ofcapacitor cells; and at least two of the plurality of thermoelectricdevices are arranged to heat and cool the plurality of battery cells.17. The battery and capacitor assembly of claim 15, wherein each of theplurality of thermoelectric devices is aligned with one of the pluralityof battery cells and the plurality of capacitor cells which thethermoelectric devices are configured to heat and cool.
 18. The batteryand capacitor assembly of claim 14, further comprising a temperaturedistribution plate disposed between the plurality of thermoelectricdevices and the cell stack and in contact with at least one of thecooling plate and the plurality of thermoelectric devices, wherein theplurality of thermoelectric devices are in contact with the coolingplate.
 19. The battery and capacitor assembly of claim 18, wherein theplurality of thermoelectric devices are disposed within pockets in thecooling plate, and the temperature distribution plate captures theplurality of thermoelectric devices within the pockets.
 20. The batteryand capacitor assembly of claim 19, wherein the temperature distributionplate is partially inset in the cooling plate.
 21. The battery andcapacitor assembly of claim 18, further comprising a plurality ofheatsink plates disposed between adjacent ones of the plurality ofbattery cells and the plurality of capacitor cells and arranged totransfer heat to and from the temperature distribution plate throughconduction.
 22. The battery and capacitor assembly of claim 21, whereineach of the plurality of heatsink plates includes a plate-like bodydisposed between adjacent ones of the plurality of battery cells and theplurality of capacitor cells, and a flange that transfers heat to andfrom the temperature distribution plate through conduction using atleast one of: direct contact with the temperature distribution plate;and a filler material disposed between the flange and the temperaturedistribution plate.